Reverse Engineering of Passenger Jets – Classified Design Parameters

Master Thesis

Hochschule fur Angewandte Wissenschaften Hamburg

Hamburg University of Applied Sciences

Department Fahrzeugtechnik und Flugzeugbau

Reverse Engineering of Passenger Jets -
Classified Design Parameters

Emiel De Grave

Examiner: Prof. Dr.-lng Dieter Scholz, MSME

August 2017

i

Reverse Engineering of Passenger Jets - Hochschule fur Angewandte Wissenschaften Hamburg

Hamburg University of Applied Sciences

Classified Design Parameters Department Fahrzeugtechnik und Flugzeugbau

Erasmus Hamburg (Germany)

Rotterdam

serpen

oDusseldorf

Keulen

Gento

Brussel

Mannheim

Rostock

Amsterdam

Den Haago

Lubeck

Hannover

o

Dortmund

oWolfsburg
Braunschweig

Berlijn

®

o

Potsdam

oMaagdenburg

Leipzig

Dresden

Frankfurt
am Main

Neurenberg

o

Karlsruhe

2

Reverse Engineering of Passenger Jets -
Classified Design Parameters

Master Thesis

Reverse Engineering
Passenger Jets
Classified

Hochschule fur Angewandte Wissenschaften Hamburg

Hamburg University of Applied Sciences

Department Fahrzeugtechnik und Flugzeugbau

Design Parameters

Reverse Engineering of Passenger Jets -
Classified Design Parameters

Design Parameters

Maximum lift coefficient: C L max

* Landing

• Take-off

Lift-to-drag ratio: E

Hochschule fur Angewandte Wissenschaften Hamburg

Hamburg University of Applied Sciences

Department Fahrzeugtechnik und Flugzeugbau

Specific fuel consumption: SFC

Reverse Engineering of Passenger Jets - Hochschule fur Angewandte Wissenschaften Hamburg

Hamburg University of Applied Sciences

Classified Design Parameters Department Fahrzeugtechnik und Flugzeugbau

Content

1. Preliminary Sizing of Passenger Aircraft

2. Concept Reverse Engineering

3. Reverse Engineering of Preliminary Sizing

4. Tool

5. Example

Reverse Engineering of Passenger Jets - Hochschule fur Angewandte Wissenschaften Hamburg

Hamburg University of Applied Sciences

Classified Design Parameters Department Fahrzeugtechnik und Flugzeugbau

Preliminary Sizing of Passenger Aircraft

Aircraft design parameters

• Take-off mass

• Fuel mass

• Operating empty mass

• Wing area

• Take-off thrust

Reverse Engineering of Passenger Jets - Hochschule fur Angewandte Wissenschaften Hamburg

Hamburg University of Applied Sciences

Classified Design Parameters Department Fahrzeugtechnik und Flugzeugbau

Preliminary Sizing of Passenger Aircraft

1. Landing

2. Take-off

3. Second Segment

4. Missed Approach

5. Cruise

Acc. to Federal Air Regulations (FAR Part 25)

Reverse Engineering of Passenger Jets - Hochschule fur Angewandte Wissenschaften Hamburg

Hamburg University of Applied Sciences

Classified Design Parameters Department Fahrzeugtechnik und Flugzeugbau

Preliminary Sizing of Passenger Aircraft

8

Reverse Engineering of Passenger Jets - Hochschule fur Angewandte Wissenschaften Hamburg

Hamburg University of Applied Sciences

Classified Design Parameters Department Fahrzeugtechnik und Flugzeugbau

Preliminary Sizing - Landing

-Landing distance-«-|

--FAR landing field length

m MTO

Svjr

k L' a ' S LFL ' C L,max,L

kt. — 0,107 kp/m 3

m MT0

m ML

9

Reverse Engineering of Passenger Jets - Hochschule fur Angewandte Wissenschaften Hamburg

Hamburg University of Applied Sciences

Classified Design Parameters Department Fahrzeugtechnik und Flugzeugbau

Preliminary Sizing - Take-Off

Tto

m T0 ■ g

m T o

Cl, max,TO ' s TOFL $W

m T o

s w

a—

k

C L , max ,To 1 s T0FL
to = 2,34 m 3 /kg

10

Reverse Engineering of Passenger Jets -
Classified Design Parameters

Department Fahrzeugtechnik und Flugzeugbau

Hochschule fur Angewandte Wissenschaften Hamburg

Hamburg University of Applied Sciences

Preliminary Sizing - 2nd Segment

Start: retracted landing gear
End: altitude of 400 ft
Flaps: take-off configuration

Req.: minimum climb gradient can be maintained
(with 1 inoperative engine)

11

Reverse Engineering of Passenger Jets -
Classified Design Parameters

Hochschule fur Angewandte Wissenschaften Hamburg

Hamburg University of Applied Sciences

Department Fahrzeugtechnik und Flugzeugbau

Preliminary Sizing - Missed Approach

Abort landing -» climb & turnaround

Flaps: landing configuration + extended landing
gear

Req.: minimum climb gradient can be maintained
(with 1 inoperative engine)

T'tO _ n E (1 . \( m ML \

rriMTO -g- n E - l \E Sm Yma ) [ttimto)

12

Reverse Engineering of Passenger Jets - Hochschule fur Angewandte Wissenschaften Hamburg

Hamburg University of Applied Sciences

Classified Design Parameters Department Fahrzeugtechnik und Flugzeugbau

Preliminary Sizing - Cruise
1. Thrust-to-weight ratio

Designed to reach destination (range)

Breguet range eq.:

13

Reverse Engineering of Passenger Jets -
Classified Design Parameters

Hochschule fur Angewandte Wissenschaften Hamburg

Hamburg University of Applied Sciences

Department Fahrzeugtechnik und Flugzeugbau

Preliminary Sizing - Cruise

1. Thrust-to-weig ht ratio

-» Fly at minimum drag speed: V md ( E max)

-> Fly at max. range speed: V

'[mto _ 1

m MTO ■ 9 (Tcr\. p

\Tto)

T 1

= (0,0013/i - 0,0397) — ■ h CR - 0,0248/i + 0,7125

/ t/i K7YL

14

Reverse Engineering of Passenger Jets - Hochschule fur Angewandte Wissenschaften Hamburg

Hamburg University of Applied Sciences

Classified Design Parameters Department Fahrzeugtechnik und Flugzeugbau

Preliminary Sizing

- Cruise

2. Wing loading

Cruise: lift - weight

m MTO _

S W

C L ■ M 2 Y
- L —

9 2

II

15

Reverse Engineering of Passenger Jets - Hochschule fur Angewandte Wissenschaften Hamburg

Hamburg University of Applied Sciences

Classified Design Parameters Department Fahrzeugtechnik und Flugzeugbau

Preliminary Sizing - Cruise

2. Wing Loading

Reverse Engineering of Passenger Jets - Hochschule fur Angewandte Wissenschaften Hamburg

Hamburg University of Applied Sciences

Classified Design Parameters Department Fahrzeugtechnik und Flugzeugbau

Preliminary Sizing - Matching Chart

17

Reverse Engineering of Passenger Jets - Hochschule fur Angewandte Wissenschaften Hamburg

Hamburg University of Applied Sciences

Classified Design Parameters Department Fahrzeugtechnik und Flugzeugbau

Concept Reverse Engineering

Def.: RE is a proces, used to understand the
working of a product and to analyze its design

Provides documentation:

* Specifications

* Mechanisms

* Materials

* Manufacturability

* Assembly details

18

Reverse Engineering of Passenger Jets - Hochschule fur Angewandte Wissenschaften Hamburg

Hamburg University of Applied Sciences

Classified Design Parameters Department Fahrzeugtechnik und Flugzeugbau

Concept Reverse Engineering

RE is applied when technical data is:

* Lost

* Not exising

* Property of another manufacturer
Note: copyright!

19

Reverse Engineering of Passenger Jets - Hochschule fur Angewandte Wissenschaften Hamburg

Hamburg University of Applied Sciences

Classified Design Parameters Department Fahrzeugtechnik und Flugzeugbau

Concept Reverse Engineering

Black-box (hypothetical)

Input Black-box Output

20

Reverse Engineering of Passenger Jets - Hochschule fur Angewandte Wissenschaften Hamburg

Hamburg University of Applied Sciences

Classified Design Parameters Department Fahrzeugtechnik und Flugzeugbau

Concept Reverse Engineering

Black-box (hypothetical)

Input Black-box Output

21

Reverse Engineering of Passenger Jets - Hochschule fur Angewandte Wissenschaften Hamburg

Hamburg University of Applied Sciences

Classified Design Parameters Department Fahrzeugtechnik und Flugzeugbau

Concept Reverse Engineering

Black-box (hypothetical)

Input Black-box Output

22

Reverse Engineering of Passenger Jets -
Classified Design Parameters

Hochschule fur Angewandte Wissenschaften Hamburg

Hamburg University of Applied Sciences

Department Fahrzeugtechnik und Flugzeugbau

Concept Reverse Engineering

White-box

Input White-box Output

23

Reverse Engineering of Passenger Jets -
Classified Design Parameters

Hochschule fur Angewandte Wissenschaften Hamburg

Hamburg University of Applied Sciences

Department Fahrzeugtechnik und Flugzeugbau

Concept Reverse Engineering

White-box

Input White-box Output

24

Reverse Engineering of Passenger Jets - Hochschule fur Angewandte Wissenschaften Hamburg

Hamburg University of Applied Sciences

Classified Design Parameters Department Fahrzeugtechnik und Flugzeugbau

Concept Reverse Engineering

White-box

Input White-box Output

25

Reverse Engineering of Passenger Jets -
Classified Design Parameters

Hochschule fur Angewandte Wissenschaften Hamburg

Hamburg University of Applied Sciences

Department Fahrzeugtechnik und Flugzeugbau

Concept Reverse Engineering

RE white-box

Input White-box Output

26

Reverse Engineering of Passenger Jets -
Classified Design Parameters

Hochschule fur Angewandte Wissenschaften Hamburg

Hamburg University of Applied Sciences

Department Fahrzeugtechnik und Flugzeugbau

Concept Reverse Engineering

RE white-box

Input White-box Output

27

Reverse Engineering of Passenger Jets - Hochschule fur Angewandte Wissenschaften Hamburg

Hamburg University of Applied Sciences

Classified Design Parameters Department Fahrzeugtechnik und Flugzeugbau

Concept Reverse Engineering

RE white-box

Input White-box Output

28

Reverse Engineering of Passenger Jets - Hochschule fur Angewandte Wissenschaften Hamburg

Hamburg University of Applied Sciences

Classified Design Parameters Department Fahrzeugtechnik und Flugzeugbau

Reverse Engineering of Preliminary Sizing

SFC

29

Reverse Engineering of Passenger Jets -
Classified Design Parameters

Hochschule fur Angewandte Wissenschaften Hamburg

Hamburg University of Applied Sciences

Department Fahrzeugtechnik und Flugzeugbau

Reverse Engineering of Preliminary Sizing

RE white-box 1

k L = 0,107 kg/m■

30

Reverse Engineering of Passenger Jets -
Classified Design Parameters

Hochschule fur Angewandte Wissenschaften Hamburg

Hamburg University of Applied Sciences

Department Fahrzeugtechnik und Flugzeugbau

Reverse Engineering of Preliminary Sizing

RE white-box 2

•max,TO

Cl,

TO

max,TO ~

o ■ s TOFL

m MTp /-fry

T Tof m TO ' 9

31

Reverse Engineering of Passenger Jets - Hochschule fur Angewandte Wissenschaften Hamburg

Hamburg University of Applied Sciences

Classified Design Parameters Department Fahrzeugtechnik und Flugzeugbau

Reverse Engineering of Preliminary Sizing

RE white-box 3

32

Reverse Engineering of Passenger Jets - Hochschule fur Angewandte Wissenschaften Hamburg

Hamburg University of Applied Sciences

Classified Design Parameters Department Fahrzeugtechnik und Flugzeugbau

Reverse Engineering of Preliminary Sizing

RE white-box 3

TO

m MTO ’ 9

(v \ 2 + {vj

VW

tf£5c • (0,0576#t -1,76)

a _ m MTO

* * sr~

GB

2\ 5,258

7r • A • e • M 2 • y • p 0

2 -

mMTO-9

(v\ 2 + Gw)

Iw

C-^mk) • (0,0328/1 - 1,05) +1 = 0

33

Reverse Engineering of Passenger Jets - Hochschule fur Angewandte Wissenschaften Hamburg

Hamburg University of Applied Sciences

Classified Design Parameters Department Fahrzeugtechnik und Flugzeugbau

Reverse Engineering of Preliminary Sizing

RE white-box 4

34

Reverse Engineering of Passenger Jets -
Classified Design Parameters

Hochschule fur Angewandte Wissenschaften Hamburg

Hamburg University of Applied Sciences

Department Fahrzeugtechnik und Flugzeugbau

Reverse Engineering of Preliminary Sizing

RE white-box 4

SFC =

E ■ In

ItlpL . m OE
m MTO m MTO

Mff'CLB ' Mff'DES

g ‘{ V C r ES + tloiter )

35

Reverse Engineering of Passenger Jets - Hochschule fur Angewandte Wissenschaften Hamburg

Hamburg University of Applied Sciences

Classified Design Parameters Department Fahrzeugtechnik und Flugzeugbau

Reverse Engineering of Preliminary Sizing

RE white-box 4

36

Reverse Engineering of Passenger Jets - Hochschule fur Angewandte Wissenschaften Hamburg

Hamburg University of Applied Sciences

Classified Design Parameters Department Fahrzeugtechnik und Flugzeugbau

Reverse Engineering of Preliminary Sizing

RE white-box 4

E ■ In

1 Vfuel,capacity ' Pfuel

m MTO

SFC = —

.Mffjo ' Mff'CLB " MffjES ' M//,L ' engine start " Mff taxi ^

ST

Ft

" r Woiter

CK

)

37

Reverse Engineering of Passenger Jets - Hochschule fur Angewandte Wissenschaften Hamburg

Hamburg University of Applied Sciences

Classified Design Parameters Department Fahrzeugtechnik und Flugzeugbau

The Tool

Necessity due to complexity:

* Amount of variables

* Mutual relations

* Numerical iteration

* Optimization solver

Tool: PJRE (Passenger Jet Reverse Engineering)

WL^Jl

38

Reverse Engineering of Passenger Jets -
Classified Design Parameters

The Tool

Requirements of PJRE

* Accurate results

* Reliable results

* Quick

* User friendly

* Multifunctional

* Direct print-out

Hochschule fur Angewandte Wissenschaften Hamburg

Hamburg University of Applied Sciences

Department Fahrzeugtechnik und Flugzeugbau

39

Reverse Engineering of Passenger Jets -
Classified Design Parameters

The Tool

Build-up

1. Specs + RE

2. C Lmax

3. E m ax

4. SFC

5. Matching Chart

6. Data

7. Verification

Hochschule fur Angewandte Wissenschaften Hamburg

Hamburg University of Applied Sciences

Department Fahrzeugtechnik und Flugzeugbau

40

Reverse Engineering of Passenger Jets -
Classified Design Parameters

Hochschule fur Angewandte Wissenschaften Hamburg

Hamburg University of Applied Sciences

Department Fahrzeugtechnik und Flugzeugbau

The Tool

Demonstration A320-200 (Airbus)

41

Reverse Engineering of Passenger Jets - Hochschule fur Angewandte Wissenschaften Hamburg

Hamburg University of Applied Sciences

Classified Design Parameters Department Fahrzeugtechnik und Flugzeugbau

Example BAe 146-200 (British Aerospace)

Reverse Engineering of Passenger Jets - Hochschule fur Angewandte Wissenschaften Hamburg

Hamburg University of Applied Sciences

Classified Design Parameters Department Fahrzeugtechnik und Flugzeugbau

Example BAe 146-200 (British Aerospace)

Google: ‘Airport planning’ + aircraft manufacturer
https://www.skybrarv.aero/index.php/Category:Aircraft

https://booksite.elsevier.com/978034Q741528/appendices/data-

a/default.htm

https://booksite.elsevier.com/978034Q741528/appendices/data-

b/defauit.htm

http://www.jet-engine.net/

Note: mission fuel fraction for climb = 0,998!

43

Reverse Engineering of Passenger Jets - Hochschule fur Angewandte Wissenschaften Hamburg

Hamburg University of Applied Sciences

Classified Design Parameters Department Fahrzeugtechnik und Flugzeugbau

Example BAe 146-200 (British Aerospace)

C|_,max,L - 3,62
^L,max,TO = 2,63

^max “ 14,5
SFC = 19,5 mg/N/s

*.. 41 n ^

brussels airlines

, \ * ■ vS S ' . ...

Reverse Engineering of Passenger Jets - Hochschule fur Angewandte Wissenschaften Hamburg

Hamburg University of Applied Sciences

Classified Design Parameters Department Fahrzeugtechnik und Flugzeugbau

Example BAe 146-200 (British Aerospace)

45

Reverse Engineering of Passenger Jets - Hochschule fur Angewandte Wissenschaften Hamburg

Hamburg University of Applied Sciences

Classified Design Parameters Department Fahrzeugtechnik und Flugzeugbau

PJRE

Positive

• Quick

• Reliable

• Accurate

• Multifunctional

• Reduces complexity

• User friendly

Negative

* Only (large) passenger jets

* Sensitive to human error

* Critical view

emiel_dg@hotmail.com

46